Curved Lever Push Button Structure for Injection Molding
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Solution Overview
Problem
Conventional push button structures face limitations in lever thickness and length, leading to reduced sensitivity, durability issues, and high production costs due to uneven injection molding, and provide a vague pressing feel to users.
Innovation Solution
A push button structure with a curved lever is developed, allowing for integrally formed casing and button body by injection molding, featuring a U-shaped, V-shaped, or other curved cross section, which enhances durability and user feedback while preventing uneven injection and adjusting for desired displacement and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lever is made thicker to enhance durability, then the strength is improved, but the elasticity is reduced which prevents the required deformation for button pressing
Solution Approach 1:
The patent applies a curved cross-section design to the lever, replacing the conventional straight rectangular cross-section with a curved profile. This curvature allows the lever to achieve both sufficient strength and adequate elasticity, as the curved geometry distributes stress more effectively while maintaining the necessary flexibility for deformation during button pressing.
2Ease of operation
If the lever is made longer to increase button displacement, then the sensitivity is improved, but the lever becomes floppy and prone to accidental triggering and breaking
Solution Approach 1:
The curved cross-section of the lever provides structural rigidity that prevents the lever from becoming floppy, while still allowing sufficient displacement for sensitive button operation. The curvature distributes bending stresses more effectively, reducing the risk of accidental triggering and breaking even when the lever is relatively long.
Solution Approach 2:
The patent changes the geometric parameters of the lever cross-section from a straight rectangular profile to a curved profile. This parameter change optimizes the balance between flexibility (for sensitivity) and rigidity (for stability), allowing the lever to be longer without becoming overly flexible or prone to failure.
3Reliability
If the lever cross-section is reduced to maintain elasticity, then the sensitivity is improved, but the injection molding speed is reduced causing defects and sink marks
Solution Approach 1:
The curved cross-section design allows for optimized material distribution that maintains lever elasticity while providing sufficient cross-sectional area for high-speed injection molding. The curved geometry enables better flow of molten plastic during injection, reducing defects and sink marks while preserving the necessary flexibility.
4Reliability
If the lever is made shorter to prevent breaking, then the durability is improved, but the button displacement is reduced giving only vague pressing feedback
Solution Approach 1:
The curved cross-section enables the lever to maintain optimal length for clear pressing feedback while resisting breaking. The curvature distributes stresses along the lever length, allowing it to be long enough to provide significant displacement and clear user feedback, yet durable enough to withstand repeated use without breaking.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The curved lever design improves durability, reduces production costs, and provides a clear pressing feel by distributing force evenly, preventing accidental triggering and increasing yield rates through controlled displacement and elasticity.
Implementation Method 1
the end of the curved lever 331 that is adjacent to the button body 33 is moved away from the opening 310, and the curved lever 331 is deformed
Data Source
AI summary
A push button structure includes a casing and a button body that are integrally formed by injection molding. The casing has an opening that extends through the surface of the casing. The button body is formed within the opening, and has an outer periphery spaced from the inner periphery of the opening and has an outer surface exposed on the surface of the casing and an inner surface extended by the curved lever. The curved lever has one end fixedly connected to an inner wall of the casing at a position adjacent to the opening such that the button body is movably positioned inside the opening. When the button body is pressed, the elasticity of the curved lever allows the button body to move toward the inside of the casing and thereby trigger an electronic switch in the casing.